Custom Aluminum Profile,Prototype Aluminum Extrusions

Custom Aluminum Profile, Prototype Aluminum Extrusions

The Complete Aluminum Extrusion Manufacturing Guide

Aluminum extrusion, akin to plastic extrusion and injection molding, is a widely used technique in the manufacturing industry. At RapidDone, we bring extensive experience in profile extrusion to serve your on-demand part manufacturing needs. This comprehensive guide will explore all aspects of the aluminum extrusion process to aid in your search for customized aluminum extrusion expertise or services. Should you have a solid project in mind and seek a supplier, reach out to RapidDone. We are dedicated to providing solutions that meet your expectations.

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Custom Aluminum Extrusion Profile Shaping

Extruded aluminum profiles are crafted based on their intended applications, typically falling into one of these seven common shapes. At RapidDone, our robust custom manufacturing capabilities allow us to produce all these types effectively.

1. Round Rod Profile

This profile features a solid circular shape, usually created with diameters up to 3.5 inches. The simplicity of the die used makes this an easy and cost-effective process.

2. Rectangular Bar Profile

This solid profile, shaped as a rectangle or square, is easy to manufacture and primarily serves smaller industries requiring aluminum pieces.

3. Round Tube Profile

Widely used in construction and power industries, this profile is a circular (or oval) hollow shape, available in a variety of inside and outside diameters.

4. Rectangular Tube Profile

Similar to the round tube but with a rectangular hollow shape, this profile finds application in structural supports and machine components.

5. T-slotted Profiles

Optimized for maximum rigidity while being lightweight, T-slotted profiles, such as the popular 80/20 and 40/40 profiles, are used in industrial applications, CNC equipment, 3D printers, work tables, and more.

6. Angles Profile

Common in industrial applications, angle profiles come with either sharp or rounded edges in a variety of degrees, tailored to design specifications.

7. Zee bar Profile

Used in construction for both indoor and outdoor applications, zee bar profiles, or double angle profiles, are also components in various frames and machine parts.

The Aluminum Extrusion Die

Aluminum extrusion dies are robust steel disks with one or more openings shaped like the desired profile. These heat-treated steel dies can withstand the high pressures essential for an efficient extrusion process.

Given that extrusion dies are designed to endure immense loads, constant inspection is crucial to maintain the optimal tolerances of the extruded profile. Direct inspections and regular profile measurements ensure the highest quality in the extrusion process.

The design of the die differs for solid and hollow profile manufacturing.

1. Solid Profile Dies

A solid profile die comprises four parts: the feeder plate with flow-controlling orifices, the die plate with the profile shape, the thicker backer plate preventing profile failure during long extrusions, and the bolster plate offering maximum pressure support.

2. Hollow And Semi-hollow Dies

Hollow and semi-hollow profile dies include three parts: the mandrel shaping the internal features, the death cap with the profile shape, and the bolster plate supporting the extrusion load.

Extrusion Materials

Aluminum, with its favorable mechanical properties, is a preferred material for extrusion. Its relatively low hardness reduces the required piston force, allowing the use of smaller, less power-consuming machinery.

The favorite alloys for extrusion belong to the 6XXX series, including aluminum 6061 and 6063, which have higher magnesium and silicon content enhancing aluminum's mechanical properties.

These heat-treatable series offer high strength and corrosion resistance, and post-extrusion heat treatment typically increases their strength, making them even more suitable for various applications.